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    Problem Solution - 5 Why's Analysis: ... Here Is Our "Wheel" Life Example

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    Blasko Nikiforov
    The 5 Whys technique is used to identify the root cause of problems by repeatedly asking "Why?" It was popularized as part of the Toyota Production System. The document provides an example of a 5 Whys analysis to determine the root cause of late bicycle deliveries. It involves asking "Why?" five times to uncover that a cheaper wheel supplier with inconsistent quality was the root cause. Benefits of the technique include quickly finding root causes without statistics. It is useful for problems involving human factors or interactions in business situations.

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    Problem Solution - 5 Why's Analysis: ... Here Is Our "Wheel" Life Example

    Uploaded by

    Blasko Nikiforov
    116 views10 pages
    The 5 Whys technique is used to identify the root cause of problems by repeatedly asking "Why?" It was popularized as part of the Toyota Production System. The document provides an example of a 5 Whys analysis to determine the root cause of late bicycle deliveries. It involves asking "Why?" five times to uncover that a cheaper wheel supplier with inconsistent quality was the root cause. Benefits of the technique include quickly finding root causes without statistics. It is useful for problems involving human factors or interactions in business situations.

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    VH Metal 5why

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    The 5 Whys technique is used to identify the root cause of problems by repeatedly asking "Why?" It was popularized as part of the Toyota Production System. The document provides an example of a 5 Whys analysis to determine the root cause of late bicycle deliveries. It involves asking "Why?" five times to uncover that a cheaper wheel supplier with inconsistent quality was the root cause. Benefits of the technique include quickly finding root causes without statistics. It is useful for problems involving human factors or interactions in business situations.

    Copyright:

    © All Rights Reserved
    Download as XLSX, PDF, TXT or read online from Scribd
    Download as xlsx, pdf, or txt
    116 views10 pages

    Problem Solution - 5 Why's Analysis: ... Here Is Our "Wheel" Life Example

    Uploaded by

    Blasko Nikiforov
    The 5 Whys technique is used to identify the root cause of problems by repeatedly asking "Why?" It was popularized as part of the Toyota Production System. The document provides an example of a 5 Whys analysis to determine the root cause of late bicycle deliveries. It involves asking "Why?" five times to uncover that a cheaper wheel supplier with inconsistent quality was the root cause. Benefits of the technique include quickly finding root causes without statistics. It is useful for problems involving human factors or interactions in business situations.

    Copyright:

    © All Rights Reserved
    Download as XLSX, PDF, TXT or read online from Scribd
    Download as xlsx, pdf, or txt
    of 10
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    The 5 Whys technique is presented as a method for getting to the root cause of problems quickly through iterative questioning. A fishbone diagram is also introduced as a visual tool to help identify potential root causes.

    The 5 Whys technique is discussed, which involves asking "Why?" five times to get to the underlying root cause of an issue.

    The steps are to: 1) Identify the problem, 2) Ask "Why?" until the root cause is determined, 3) Document each level of "Why?" on the 5 Whys worksheet.

    Problem Solution - 5 Why's Analysis

    5 whys as part of lean manufacturing is a problem solving technique that allows you to get at the root cause of a problem fairly quickly. It was made popular as part of the To

    Benefits Of The 5 Whys.


    It helps to quickly identify the root cause of a problem.
    It helps determine the relationship between different root causes of a problem.
    It can be learned quickly and doesn't require statistical analysis to be used.
    When Is 5 Whys Most Useful?
    When problems involve human factors or interactions.
    In all types of business situations whether solving a lean manufacturing or for any other business problem.
    Example of a five Why Analysis. ...Here is our "wheel" life example.
    1. Why is our largest customer unhappy? Because our deliveries of bicycles have been late for the last month.
    2. Why have our bicycle deliveries been late for the last month? Because production has been behind schedule.
    3. Why has production been behind schedule? Because there is a shortage of wheels.
    4. Why are we having a shortage of wheels? Because incoming inspection has rejected a large number of wheels for not being round.
    5. Why are we rejecting so many parts? Because purchasing switched to a cheaper wheel supplier that has inconsistent quality.

    Problem Solution - 5 Why's Analysis Worksheet


    Part Number:

    Date:

    Area:

    Product/Process:

    Problem Description:

    Use this route to specify the nonconformity that is being investigated.

    Root Causes

    Corrective Ac
    Responsib

    Therefore
    Why?

    the operator picked it not knowing its a wrong item

    Therefore

    Why?
    the incorrect item was placed on the locati Therefore

    Why?
    Therefore

    Why?

    Use this route to investigate why the problem wasnt


    detected

    Therefore
    Why?

    Therefore
    Why?

    Why?

    Therefore
    Why?
    Therefore
    Why?
    Therefore

    Why?

    Use this route to investigate the root cause of the system.

    Therefore
    Why?

    Therefore
    Why?

    Why?

    Therefore
    Why?
    Therefore
    Why?
    Therefore

    Why?
    Therefore
    Why?
    Why?
    Problem Solution Completed:

    Solution Date:

    Break point of the change in the process:

    Problem Solution Completed:

    Solution Date:

    Break point of the change in the process:

    Why's Analysis

    se of a problem fairly quickly. It was made popular as part of the Toyota Production System (1970s.) Application of the strategy involves taking any problem and asking Why - what

    ate for the last month.


    s been behind schedule.

    a large number of wheels for not being round.

    el supplier that has inconsistent quality.

    Analysis Worksheet
    Product/Process:

    Corrective Action &


    Responsibility
    A

    Implementation Date:

    Date

    Implementation Date:

    Fishbone
    Root Cause Identification Tool
    (complete for product involved in quality issue)

    Machine

    Man

    Material

    Problem
    Statement

    Method

    Environment

    Manpower

    Cause and Effect (Fishbone Diagrams)


    A cause and effect (fishbone) diagram:

    Breaks problems down into bite-size pieces.


    Displays many possible causes in a graphic manner.
    Is also called a cause & effect, 4-M or Ishikawa diagram.
    Shows how various causes interact.
    Follows brainstorming rules when generating ideas.

    A fishbone session is divided into three parts: Brainstorming, prioritizing, and development of an action plan. Identify the problem statement and
    brainstorm the categories in a fishbone diagram. To prioritize problem causes, polling is often used. The three most probable causes may be circled for
    the development of an action plan.
    Generally, the 4-M (manpower, material, method, machine) version of the fishbone diagram will suffice. Occasionally, the expanded version must be
    used. In a laboratory environment, measurement is a key issue. When discussing the brown grass in the lawn, environment is important. A 5-M and E
    Schematic is shown in the above illustration.

    Material

    Machine

    Man
    Insufficient Training

    Variation in Tolerance
    1. Plating

    Keypunch errors

    Wear and Tear

    2. Material thickness

    1. Worn numbers on scale keys

    3. Scrap & Foreign Elements

    2. Containers broken

    Over Issue updates not made


    Pulled wrong parts from location

    4. Lengths

    Scale #2 more accurate


    than scale #1

    Wrong part numbers from dept

    Suspect pan tare weights

    Pulled wrong parts from location

    Scale Calibration
    Three different scales

    Vendor counts accepted


    Non-standard sampling procedure
    (inadequate sample quantity)

    Pulled wrong parts from location

    Tare weights not on pans

    Measurement

    Reduce incoming
    receipt errors from 4%
    to 1% of transactions

    Interruptions

    Environment

    Method

    IS-IS NOT MATRIX


    Problem:

    What occurs, what objects


    are affected?
    Where does the problem
    occur?
    When does the problem
    occur?

    Extent of problems

    Who is involved?

    Is

    Is Not

    Distinctions

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